USRE46145E1 - Uniformly, highly dispersed metal catalyst and process for producing the same - Google Patents

Uniformly, highly dispersed metal catalyst and process for producing the same Download PDF

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USRE46145E1
USRE46145E1 US13/940,053 US200613940053A USRE46145E US RE46145 E1 USRE46145 E1 US RE46145E1 US 200613940053 A US200613940053 A US 200613940053A US RE46145 E USRE46145 E US RE46145E
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catalyst
sulfur
metal
carrier
alumina
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Yoshimi Okada
Toshiji Makabe
Masashi Saito
Hiroaki Nishijima
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Chiyoda Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
    • B01J27/02—Sulfur, selenium or tellurium; Compounds thereof
    • B01J27/053—Sulfates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/02—Boron or aluminium; Oxides or hydroxides thereof
    • B01J21/04—Alumina
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J23/42—Platinum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J23/46—Ruthenium, rhodium, osmium or iridium
    • B01J23/464—Rhodium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
    • B01J27/02—Sulfur, selenium or tellurium; Compounds thereof
    • B01J27/04—Sulfides
    • B01J27/043—Sulfides with iron group metals or platinum group metals
    • B01J27/045—Platinum group metals
    • B01J35/1019—
    • B01J35/1038—
    • B01J35/1061—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/61—Surface area
    • B01J35/615—100-500 m2/g
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/63—Pore volume
    • B01J35/633—Pore volume less than 0.5 ml/g
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/64—Pore diameter
    • B01J35/647—2-50 nm
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/0201—Impregnation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/16—Reducing
    • B01J37/18—Reducing with gases containing free hydrogen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/20—Sulfiding
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C15/00—Cyclic hydrocarbons containing only six-membered aromatic rings as cyclic parts
    • C07C15/02—Monocyclic hydrocarbons
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C15/00—Cyclic hydrocarbons containing only six-membered aromatic rings as cyclic parts
    • C07C15/02—Monocyclic hydrocarbons
    • C07C15/06—Toluene
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C15/00—Cyclic hydrocarbons containing only six-membered aromatic rings as cyclic parts
    • C07C15/20—Polycyclic condensed hydrocarbons
    • C07C15/24—Polycyclic condensed hydrocarbons containing two rings
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C15/00—Cyclic hydrocarbons containing only six-membered aromatic rings as cyclic parts
    • C07C15/20—Polycyclic condensed hydrocarbons
    • C07C15/27—Polycyclic condensed hydrocarbons containing three rings
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C5/00—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
    • C07C5/32—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with formation of free hydrogen
    • C07C5/367—Formation of an aromatic six-membered ring from an existing six-membered ring, e.g. dehydrogenation of ethylcyclohexane to ethylbenzene
    • B01J35/008—
    • B01J35/0093—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/30—Catalysts, in general, characterised by their form or physical properties characterised by their physical properties
    • B01J35/396—Distribution of the active metal ingredient
    • B01J35/397—Egg shell like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/30—Catalysts, in general, characterised by their form or physical properties characterised by their physical properties
    • B01J35/396—Distribution of the active metal ingredient
    • B01J35/399—Distribution of the active metal ingredient homogeneously throughout the support particle
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/50—Improvements relating to the production of bulk chemicals
    • Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts

Definitions

  • the present invention relates to a metal loaded catalyst for use in manufacturing chemical products, producing hydrogen, cleaning the environment, such as cleaning exhaust gas, etc. More especially, the present invention relates to a uniformly, highly dispersed metal loaded catalyst in which sulfur or a sulfur compound are substantially uniformly dispersed throughout the cross section of a catalyst carrier and catalyst metal is loaded on the carrier in a state where the catalyst metals are substantially uniformly dispersed throughout the cross section of the carrier almost substantially in agreement with the distribution of the sulfur or sulfur compound, a method of using the same, and a sulfur-containing porous metal oxide for use in producing the same.
  • a metal loaded catalyst in which various catalytic metal species are loaded on a catalyst carrier made of a metal oxide is used in an extremely wide range of fields, for example, not only dehydrogenation reaction in which hydrogenated aromatics such as methylcyclohexane, cyclohexane, and decalin are dehydrogenated into the corresponding aromatics and hydrogen but also manufacturing of chemical products and fuels by dehydrogenation reaction of various compounds, hydrogenation reaction which is a reverse reaction of the dehydrogenation reaction and reforming reaction; and environmental clean-up such as cleaning automobile exhaust gas, and the like.
  • such metal loaded catalysts are manufactured as follows: a porous catalyst carrier made of a metal oxide such as alumina or silica etc., is prepared; when platinum is loaded on the obtained porous catalyst carrier, the obtained porous catalyst carrier is impregnated with a solution of a catalyst metal compound, such as a chloroplatinic acid aqueous solution, a platinum ammonium chloride aqueous solution, and a solution of an organoplatinum compound such as platinum acetylacetonate; the resultant is dried to form a dried matter loading the catalyst metal compound; the dried matter is calcined, e.g., at 350 to 800° C.
  • a catalyst metal compound such as a chloroplatinic acid aqueous solution, a platinum ammonium chloride aqueous solution, and a solution of an organoplatinum compound such as platinum acetylacetonate
  • the resultant is dried to form a dried matter loading the catalyst metal compound
  • the dried matter is calcined,
  • the obtained calcined matter loading the catalyst metal compound is subjected to hydrogen reduction, e.g., at 250 to 800° C. for 0.5 to 24 hours.
  • the metal loaded catalyst manufactured by such a procedure has the following problems.
  • a platinum-loaded alumina catalyst in which platinum, being one of typical active metal species as catalyst metal, is loaded on an alumina carrier, being used most widely as a catalyst carrier is taken as an example, it is known that since the adsorbability of a platinum compound to the alumina carrier is high, the platinum compound is adsorbed and fixed as it is to the outer shell part of the alumina carrier before the platinum compound is dispersed inside the alumina carrier, which forms a so-called egg shell-type metal loaded catalyst, as viewed in the cross section, the catalyst metal being loaded only on the outer shell part and no catalytic metal species being loaded inside the carrier (see 14th “Catalysis School Text” (2003), pages 35 to 44 and 15th “Catalysis School Text” (2004), pages 35 to 44, organized by Kanto Branch Commission, Catalysis Society of Japan).
  • the reaction occurs preferentially in the outer shell of the catalyst.
  • the egg shell-type catalyst is advantageous in such a reaction.
  • the density of the active metal particles increase, which presumably leads to possibilities that the active metal particles can not be sufficiently dispersed, catalyst deactivation due to sintering or coking is likely to occur, etc. Therefore, in a reaction which is not influenced by the dispersion resistance, it is presumably advantageous to design a catalyst in such a manner as to reduce the influences by fully utilizing the surface area of a carrier.
  • the inventors of the present invention carried out extensive research on loading catalyst metal such as platinum on a catalyst carrier such as alumina or silica in a state where the catalyst metal is uniformly dispersed as far as the inside of the catalyst carrier by an impregnation method.
  • catalyst metal such as platinum
  • a catalyst carrier such as alumina or silica
  • catalyst metal is loaded substantially in agreement with the distribution of the sulfur or sulfur compound, thereby easily obtaining a uniformly, highly dispersed metal loaded catalyst in which the catalytic metal is substantially uniformly dispersed and loaded over the entire cross section of the catalyst carrier, and thus the present invention has been accomplished.
  • the present invention aims to provide a uniformly, highly dispersed metal catalyst in which the catalytic metal is loaded on the catalyst carrier in a state where the catalytic metal is substantially uniformly dispersed throughout the cross section of the catalyst carrier and which has excellent performances in terms of catalytic activity, selectivity, life, etc.
  • the present invention also aims to provide a method of producing such a uniformly, highly dispersed metal catalyst which has excellent performances in terms of catalytic activity, selectivity, life, etc., a method of using the same, and a sulfur-containing porous metal oxide for use in the method of producing the same.
  • the present invention provides a uniformly, highly dispersed metal catalyst including: a catalyst carrier made of a metal oxide; and a catalyst metal having catalytic activity, the catalyst metal being loaded on the catalyst carrier, in which: the catalyst carrier is a sulfur-containing catalyst carrier containing sulfur or a sulfur compound which is dispersed throughout across section of the carrier; and in the sulfur-containing catalyst carrier, the catalyst metal is dispersed and loaded over an entire cross section of the catalyst carrier substantially in agreement with distribution of the sulfur or the sulfur compound.
  • the present invention provides a method of producing a uniformly, highly dispersed metal catalyst including: preparing a sulfur-containing catalyst carrier in which sulfur or a sulfur compound is dispersed throughout a cross section thereof; impregnating the obtained sulfur-containing catalyst carrier with an aqueous solution of catalyst metal compound and drying the resulting catalyst carrier to obtain a dried matter loading the catalyst metal compound; reducing the dried matter loading the catalyst metal compound as it is in a hydrogen atmosphere or calcining the dried matter loading the catalyst metal compound to obtain a calcined matter loading catalyst metal; and reducing the obtained calcined matter loading the catalyst metal with hydrogen.
  • the wording “uniform-type” used in the uniformly dispersed metal catalyst of the present invention refers to a state where catalyst metal particles are substantially uniformly loaded over the entire cross section of the catalyst carrier, and the wording “highly dispersed” refers to a state where the particle diameter of the loaded metal is sufficiently small and the particle is dispersed to a high degree.
  • the uniformly, highly dispersed metal catalyst of the present invention refers to a uniformly, highly dispersed metal catalyst in which: the numerical value of a metal dispersion degree, which will be mentioned later, is high; and the metal particles are substantially uniformly loaded over the entire cross section of the catalyst carrier while a high dispersion state, in which the particle diameter of the loaded metal is sufficiently small, is maintained.
  • metal oxides used for a catalyst carrier in the present invention include metal oxides containing one or two or more metals selected from aluminum (Al), silicon (Si), zirconium (Zi), magnesium (Mg), calcium (Ca), titanium (Ti), vanadium (Va), chromium (Cr), manganese (Mn), iron, (Fe), cobalt (Co), nickel (Ni), copper (Cu), zinc (Zn), gallium (Ga), yttrium (Y), niobium (Nb), molybdenum (Mo), tungsten (W), lanthanum (La), and cerium (Ce).
  • Alumina, silica, titania, zirconia, ceria, and the like are preferred.
  • a porous ⁇ -alumina carrier is preferable as disclosed in JP 06-72005 B, for example.
  • the porous ⁇ -alumina carrier is obtained by washing by filtration a slurry of aluminum hydroxide generated by neutralizing aluminum salt, dehydrating and drying the obtained alumina hydrogel, and then calcining the resultant at 400 to 800° C. for about 1 to 6 hours.
  • a porous ⁇ -alumina carrier obtained through a pH swing process in which the pH of alumina hydrogel is alternately fluctuated between a pH range of the dissolution of alumina hydrogel and a pH range of the precipitation of boehmite gel and simultaneously an alumina hydrogel forming substance is added for growing crystals of the alumina hydrogel when the pH is fluctuated from at least either one of the pH ranges to the other one of the pH ranges.
  • the porous ⁇ -alumina carrier obtained through the pH swing process is excellent in the uniformity of pore distribution, and excellent in that the physical properties of each pellet are stable because there is less variation in the physical properties also in the alumina carrier pellet after the formation of the carrier.
  • sulfur or sulfur compound there is no limitation on the sulfur or sulfur compound to be dispersed in such a catalyst carrier beforehand for incorporation thereof insofar as the sulfur or sulfur compound has a sulfur element and can be uniformly dispersed in the catalyst carrier during the preparation of the catalyst carrier or after the preparation of the catalyst carrier.
  • sulfur crystal powders, and sulfur-containing compounds such as sulfuric acid, sulfate including ammonium sulfate can be mentioned.
  • sulfur compounds having solubility in water or an organic solvent are preferable, and sulfuric acid, ammonium sulfate, etc., can be mentioned as such sulfur compounds.
  • the amount of sulfur to be contained in a carrier is preferably 0.15% by weight or more and 5% by weight or less, and more preferably 0.15% by weight or more and 3% by weight or less.
  • the sulfur content is less than 0.15% by weight, the degree that metal is uniformly loaded as far as the center of the catalyst is low, while when the sulfur content exceeds 5% by weight, a problem is likely to occur that sulfur is likely to locally agglomerate and metal is not dispersed and loaded on such a portion.
  • the most suitable sulfur content range is preferably 0.15 to 3.0% by weight considering the effect that metal is uniformly dispersed and loaded.
  • a method of preparing a sulfur-containing catalyst carrier containing the above-mentioned sulfur or sulfur compound usable is a method capable of incorporating the sulfur or sulfur compound in a state where the sulfur or sulfur compound is uniformly dispersed throughout the cross section of the carrier.
  • method A involving kneading sulfur powder in a metal hydroxide gel serving as a precursor of a metal oxide obtained when preparing a catalyst carrier, forming the resultant into a predetermined shape, and drying and calcining the resultant
  • method B involving preparing a metal hydroxide gel serving as a precursor of a metal oxide containing sulfur using metal sulfate and/or sulfuric acid when preparing a catalyst carrier, forming the resultant into a predetermined shape, and drying and calcining the resultant
  • method C involving forming a metal hydroxide gel serving as a precursor of a metal oxide into a predetermined shape when preparing a catalyst carrier, drying the resultant to form a dry metal hydroxide gel, impregnating the dry metal oxide with a sulfur compound solution, and calcining the same
  • method D involving forming a metal hydroxide gel serving as a precursor of a metal oxide into a predetermined shape when preparing a catalyst carrier, drying
  • the calcining temperature is usually 100° C. or higher and 1,000° C. or lower, and preferably 350° C. or higher and 800° C. or lower, and the calcining time is 0.5 hour or more and 48 hours or less, and preferably 1 hour or more and 24 hours or less.
  • the calcining temperature is lower than 350° C., conversion to an oxide from a hydroxide may not be fully performed, while when the calcining temperature is higher than 800° C., the surface area after calcining may be dramatically reduced.
  • the catalyst metal to be loaded on the sulfur-containing catalyst carrier there is no limitation on the catalyst metal to be loaded on the sulfur-containing catalyst carrier, and preferable is one or two or more metals selected from platinum (Pt), palladium (Pd), iridium (Ir), rhodium (Rh), ruthenium (Ru), nickel (Ni), copper (Cu), and zinc (Zn), and more preferably is platinum.
  • the catalyst carrier is, for example, the above-mentioned porous ⁇ -alumina carrier and the catalyst metal is platinum
  • the loading amount of catalyst metal is 0.05% by weight or more and 5.0% or less, and preferably 0.1% by weight or more and 3.0% by weight or less.
  • the catalyst prepared as mentioned above may be formed into a general pellet in the forming process, or can also be fixed on a support in various forms such as a honeycomb and plate.
  • the catalyst may be fixed on a support in the preparation processes of the sulfur-containing catalyst carrier described above or catalyst powder after loading catalyst metal may be fixed thereon.
  • the sulfur-containing catalyst carrier or the catalyst to such a support can be fixed by a binder, calcining, or sintering, which are generally used for fixing an oxide catalyst to a honeycomb, a plate, etc.
  • the catalyst metal is substantially uniformly dispersed throughout the cross section of the carrier by observing quantitatively the concentration distribution of catalyst metal elements on the catalyst cross section by EPMA (Electron probe micro analyzer).
  • EPMA Electrode probe micro analyzer
  • fluorescence X rays which are peculiar to elements and generated by irradiating a sample with electron beams, are detected, and the concentration of a specific element of the electron-beam-irradiation part is quantified from the detected intensity.
  • the following analyses are possible: the surface analysis in which electron beams are emitted while shifting target irradiation portions, and the distribution states of specific elements throughout the sample cross section are indicated in different colors according to the detected intensity, whereby the distribution state thereof throughout the cross section is shown; and the line analysis which shows, in a graph, the detected intensity at the measurement position linearly traversing the sample cross section as a relative value.
  • catalyst metal is detected only in the outer shell of the cross section.
  • the detected intensity in the measurement position inside the outer shell is notably small, and the catalyst metal concentration of the center is about 1 ⁇ 2 or less compared with that of the outer shell part.
  • metal is loaded with high concentration as far as the center of the carrier cross section as well as the outer shell part of the carrier cross section.
  • the metal concentration of the center with respect to the outer shell part, the catalyst metal can be uniformly dispersed from the outer shell part to the center of the cross section of the carrier within the range of preferably ⁇ 50%, more preferably ⁇ 30%, and still more preferably ⁇ 15% in terms of the detected intensity.
  • the metal dispersion ratio is defined by the ratio of the number of metal atoms which are present on the outer face of the loaded metal particles with respect to a total number of the loaded metal atoms. For example, when metal particles containing 100 atoms are loaded, and 40 metal atoms out of the 100 atoms are present on the outer surface, the metal dispersion ratio is 40%.
  • the metal dispersion ratio is usually measured by the CO pulse adsorption method, and the measurement is carried out by a method of determining the number of CO molecules adsorbing metal atoms which are present on the outer surface.
  • the forms of the metal particles are assumed to have a form of a cube or a regular octahedron, the metal particle diameter based on the assumption can be estimated from the result.
  • the dispersion ratio of the catalyst metal of the present invention is 40% or higher, and preferably 60% or higher and 80% or lower.
  • the average metal particle size equivalent to the dispersion ratio of 60% or higher is 10 ⁇ or smaller, and the average metal particle size equivalent to the dispersion ratio of 70% is about 7 ⁇ .
  • the significances of increasing the metal dispersion ratio for reducing the size of the loaded metal particles as described above mainly reside in the following two respects. It is primarily mentioned that as the dispersion ratio of metal increases, the proportion of atoms which are present on the outer surface of metal particles increases, whereby the surface area of active metal increases, and the activity is improved.
  • the particle size of a commonly commercially-available platinum-loaded alumina catalyst is about 20 to 30 ⁇ and the metal dispersion ratio is about 20 to 40% in many cases. It is said that it is relatively difficult to load platinum in a dispersion ratio as high as 20 ⁇ or smaller.
  • a highly dispersed catalyst with a dispersion ratio of 10 ⁇ or smaller has been demanded not only from the viewpoint of increasing catalyst activity but also from the viewpoint of effectively using platinum resources. However, a catalyst having such a high dispersion ratio has not yet been prepared.
  • a porous metal oxide in which sulfur or a sulfur compound is contained preferably has the pore size controlled as uniformly as possible so that the pore distribution becomes sharp.
  • the pore sizes of the porous metal oxide are made around the same size, the pore size distribution of the porous metal oxide is sharply controlled.
  • Such a porous metal oxide is advantageous in a process of dispersing and loading sulfur and a process of dispersing and loading metal thoroughly in agreement with the distribution of sulfur.
  • the dispersion ratio of the noble metal after calcining varies depending on the pH value of an aqueous impregnation solution.
  • the optimal range of the pH value is 1.0 to 5.0, and preferably 1.8 to 3.0.
  • the pH value of an impregnation solution is lower than 1.0, the dispersion ratio of noble metal after loading is low, and when the pH value is higher than 5.0, the dispersion ratio decreases.
  • the dispersion ratio of metal becomes higher compared with the case where a metal oxide whose pores are not controlled is used for a carrier.
  • the dispersion ratio is further improved by adjusting the pH value of an aqueous solution for impregnating platinum to the optimal value.
  • the platinum-loaded alumina catalyst thus prepared forms an egg shell-type catalyst in which platinum is loaded only on the shell part of the cross section.
  • an egg shell-type platinum-loaded alumina catalyst prepared by using a porous ⁇ -alumina whose pore distribution is sharply adjusted for a carrier, and impregnating the carrier with an aqueous impregnation solution whose pH value is adjusted to the optimal value has a dispersion ratio of platinum as high as 60 to 80%, even if sulfur or a sulfur compound is not present as in the present invention.
  • treatment such as masking the remaining acid site with alkali metal is necessary for applying the catalyst to a reaction for highly inhibiting a decomposition reaction and the like.
  • the present invention makes it possible, for the first time, to prepare a uniformly, highly dispersed platinum-loaded alumina catalyst in which platinum is loaded over the entire cross section of the catalyst while maintaining the dispersion ratio as high as 60 to 80% by using an alumina carrier whose pore distribution is controlled and an aqueous platinum solution whose pH value is optimized, and dispersing sulfur or a sulfur compound throughout the cross section of the alumina carrier whose pore distribution is controlled.
  • a uniform catalyst is suitable for a system in which imparting dispersion resistance to the inside of the catalyst is suitable for a reaction, and in that since metal particles are dispersed throughout the inside of the carrier, there are distances between the metal particles, whereby the metal particles are difficult to agglomerate by sintering and the activity is less likely to deactivate by sintering.
  • particles of a noble metal such as platinum are bimetallized with a second metal components such as rhenium or tin to break the continuous arrangement of platinum atoms or the like, thereby suppressing the unnecessary adsorption of the carbon atoms of a raw material or a product and inhibiting a decomposition reaction.
  • a noble metal such as platinum
  • a second metal components such as rhenium or tin
  • the present invention can provide a metal catalyst which eliminates the necessity of masking the acid site with alkali metal.
  • active metals such as noble metals
  • repeating the impregnating processes, drying, and calcining increases the cost for industrially manufacturing a catalyst. Therefore, in the case of a catalyst not requiring the masking with alkali metal, the cost for the masking can be reduced.
  • a sulfur compound can be incorporated in a carrier by various methods as described above.
  • a sulfur compound can be incorporated in a range suitable for an alumina carrier by using a sulfur compound in a process of manufacturing an alumina carrier, and since the sulfur compound is generally inexpensive, it is possible to manufacture a carrier containing sulfur with little effect on the manufacturing cost of an alumina carrier. Therefore, the catalyst manufacturing cost is generally inexpensive as compared with the case where masking with alkali metal is carried out.
  • the above-mentioned catalyst carrier when catalyst metal is loaded on a catalyst carrier, the above-mentioned catalyst carrier may be impregnated with a solution of the above-mentioned catalyst metal, dried, and calcined at a predetermined temperature.
  • a solution of catalyst metal compound chloride, bromide, ammonium salt, carbonyl compound, of various complex compounds, an amine complex, an ammine complex, an acetylacetonato complex, of the catalyst metal can be mentioned.
  • platinum compounds such as chloroplatinic acid, platinum acetylacetonate, ammonium platinate, bromo platinate, platinum dichloride, platinum tetrachloride hydrate, platinum carbonyl dichloride, and dinitro diamine platinate are mentioned.
  • the porous ⁇ -alumina carrier is impregnated with a solution of the above-mentioned platinum compound; the resultant is dried preferably at 50° C. or higher and 200° C. or lower for 0.5 hour or more and 48 hours or less; the resultant is calcined preferably at 350° C. or higher and 600° C. or lower for 0.5 hour or more and 48 hours or less, and more preferably at 350° C. or higher and 450° C.
  • catalyst metal is loaded not only on the surface of a catalyst carrier but also over the entire cross section of the catalyst carrier, and since the loading amount of the catalyst metal can be increased while maintaining such a high dispersion ratio, the catalytic activity is improved.
  • platinum as catalyst metal is loaded on a porous ⁇ -alumina carrier as a catalyst carrier, platinum can be loaded in a dispersion ratio as high as 50% or higher until the loading amount of platinum reaches about 2% by weight.
  • the uniformly, highly dispersed metal catalyst of the present invention can be preferably used as: dehydrogenation catalysts for monocyclic hydrogenated aromatics such as cyclohexane, methylcyclohexane, and dimethylcyclohexane; bicyclic hydrogenated aromatics such as tetralin, decalin, and methyldecalin; and tricyclic hydrogenated aromatics such as tetradecahydroanthracene, which are used as a hydrogen storage for use in a hydrogen supply system according to, for example, a chemical hydride method.
  • dehydrogenation catalysts for monocyclic hydrogenated aromatics such as cyclohexane, methylcyclohexane, and dimethylcyclohexane
  • bicyclic hydrogenated aromatics such as tetralin, decalin, and methyldecalin
  • tricyclic hydrogenated aromatics such as tetradecahydroanthracene
  • a sulfur-containing porous metal oxide in which sulfur or a sulfur compound serving as a carrier of the uniformly, highly dispersed metal catalyst of the present invention is substantially uniformly dispersed throughout the cross section of the carrier can be applied not only to a catalyst carrier but also to adsorbent and the like. Since sulfur exists over the entire carrier, metal ion and the like can be rapidly adsorbed as far as the inside of an adsorbent, the uniformly, highly dispersed metal catalyst of the present invention is useful also as an adsorbent for use in recovering metal ion and the like.
  • the catalyst metal is loaded on the catalyst carrier in a state where the catalyst metal is dispersed throughout the cross section of the catalyst carrier, therefore, the loading amount of the catalyst metal increases, and excellent performances in terms of catalytic activity, selectivity, life, etc., are exhibited.
  • a uniformly, highly dispersed metal catalyst in which the catalyst metal is loaded on the catalyst carrier in a state where the catalyst metal is dispersed throughout the cross section of the catalyst carrier can be easily produced.
  • FIG. 1 illustrates carrier states of each of an egg shell-type catalyst and a uniform-type catalyst according to the classification of metal-loaded state as viewed from the catalyst cross section of metal-loaded catalysts.
  • FIG. 2 is a view illustrating a pore distribution measured by a mercury porosimetry of a carrier A according to Comparative Example of the present invention.
  • FIG. 3 is distribution measurement diagrams of a sulfur element and a platinum element measured by EPMA with respect to a 0.6 wt % platinum-loaded alumina catalyst (catalyst No. 1) using a carrier A according to Comparative Example 1 of the present invention.
  • FIG. 4 is distribution measurement diagrams of a sulfur element and a platinum element measured by EPMA with respect to a 0.6 wt % platinum-loaded alumina catalyst (catalyst No. 2) using a carrier B according to Example 1 of the present invention.
  • FIG. 5 is distribution measurement diagrams of a sulfur element and a platinum element measured by EPMA with respect to a 0.6 wt % platinum-loaded alumina catalyst (catalyst No. 3) using a carrier C according to Example 1 of the present invention.
  • FIG. 6 is a view illustrating a pore distribution measured by a mercury porosimetry of a carrier D according to Example 2 of the present invention.
  • FIG. 7 is distribution measurement diagrams of a sulfur element and a platinum element measured by EPMA with respect to a 0.6 wt % platinum-loaded alumina catalyst (catalyst No. 4) using the carrier D according to Example 2 of the present invention.
  • FIG. 8 is distribution measurement diagrams of a sulfur element and a platinum element measured by EPMA with respect to a 0.6 wt % platinum-loaded alumina catalyst (catalyst No. 5) using a carrier E according to Example 3 of the present invention.
  • FIG. 9 is distribution measurement diagrams of a sulfur element and a platinum element measured by EPMA with respect to a 0.6 wt % platinum-loaded alumina catalyst (catalyst No. 6) using a carrier F according to Example 3 of the present invention.
  • FIG. 10 is distribution measurement diagrams of a sulfur element and a platinum element measured by EPMA with respect to a 0.6 wt % platinum-loaded alumina catalyst (catalyst No. 7) using a carrier G according to Example 3 of the present invention.
  • FIG. 11 are distribution measurement diagrams of a sulfur element and a platinum element measured by EPMA with respect to each 0 . 6 wt % rhodium-loaded alumina catalyst (catalyst No. 8) prepared using the carrier A containing no sulfur according to Comparative Example of the present invention and the carrier D containing sulfur according to Example 2 of the present invention.
  • the egg shell-type refers to a state where a metal member to be loaded is dispersed and loaded only on the outer shell part of one cross section of a formed catalyst.
  • the uniform-type refers to a state where a metal member is dispersed throughout the cross section and a metal member is loaded over the entire inside of a formed catalyst.
  • 3,900 cc of aqueous aluminum nitrate solution with a concentration of 2.67 mol/L was prepared and simultaneously, 3,900 cc of 14% aqueous ammonia solution was prepared.
  • 20 L of pure water was placed in a 30-L enamel container, and the container was warmed to 70° C. under stirring. While continuing stirring, a pH swing operation in which 1,300 cc of aqueous aluminum nitrate solution was placed, followed by stirring for 5 minutes (pH2.0), and thereafter, 1,300 cc of aqueous ammonia solution was placed, followed by stirring for 5 minutes (pH 7.4) was performed 4 times.
  • An aqueous slurry solution of the obtained aluminum hydroxide was filtered to recover a cake, subjecting the cake to a washing operation in which the cake was re-dispersed in 20 L of pure water, followed by filtering again was performed 3 times, obtaining a washed gel.
  • the washed cake was air dried to adjust the moisture, and then was formed into a rod-like shape having a diameter of 1.6 mm with an extruder.
  • the resultant was dried (120° C., 3 hours), crushed to about 1 cm in length, baked in a muffle furnace (500° C., 3 hours), thereby yielding an alumina carrier A containing no sulfur.
  • the alumina carrier A thus obtained had a BET surface area of 275 m 2 /g, a pore volume of 0.65 cm 3 /g, and an average pore size of 8.9 nm, which were determined by a mercury porosimetry, and had a sharp pore distribution in which the pore sizes of almost all of the pores were concentrated near the average pore size.
  • the volume occupied by pores having a diameter of 7 to 10 nm was 80% or more of the total pore volume.
  • the pore distribution of the carrier A is shown in FIG. 2 .
  • the alumina carrier A thus prepared was impregnated with an aqueous chloroplatinic acid solution whose pH was adjusted to 2.0 so that the platinum-loaded amount after calcination was 0.6% by weight. Thereafter, moisture was removed with an evaporator, and the resultant was dried (at 120° C. for 3 hours) and calcined (at 400° C. for 3 hours). Then, the resultant was placed in a flow-type hydrogen-reducing apparatus, and hydrogen reduction was carried out at 450° C. for 15 hours in a hydrogen stream, thereby yielding a 0.6 wt % platinum-loaded alumina catalyst No. 1.
  • the pH swing operation was performed 3 times in the same manner as in the preparation of the alumina carrier A, and washing was similarly performed, yielding a washed gel.
  • Sulfur powder was added to the gel so that the sulfur powder was 0.5% by weight with respect to the weight of alumina after calcination, and uniformly kneaded. Thereafter, the resultant was formed, dried, and calcined in the same manner as in the case of the carrier A, yielding an alumina carrier B containing the sulfur powder. It should be noted that when adding the sulfur powder to the washed gel, the powder was not kneaded in the cake.
  • the sulfur powder was added under stirring to the gel in the form of high concentration slurry in which the cake was dispersed in pure water, followed by filtration, yielding an alumina carrier C containing the sulfur powder from a gel obtained by sufficiently kneading the cake with a kneader in the same manner as in the carrier B.
  • Each of the alumina carriers B and C thus prepared was impregnated with an aqueous chloroplatinic acid solution whose pH was adjusted to 2.0 so that the platinum-loaded amount after calcination was 0.6% by weight. Thereafter, moisture was removed with an evaporator, and the resultants were dried (at 120° C. for 3 hours) and calcined (at 400° C. for 3 hours). Then, the resultants were placed in a flow-type hydrogen-reducing apparatus, and hydrogen reduction was carried but at 450° C. for 15 hours in a hydrogen stream, thereby yielding 0.6 wt % platinum-loaded alumina catalysts No. 2 and No. 3.
  • 3,900 cc of aqueous aluminum sulfate solution with a concentration of 0.9 mol/L was prepared and simultaneously, 3,900 cc of 14% aqueous ammonia solution was prepared.
  • 7 L of pure water was placed in a 10 L enamel container, and the container was warmed to 70° C. under stirring. While continuing stirring, a pH swing operation in which 400 cc of aqueous aluminum sulfate solution was placed, followed by stirring for 5 minutes (pH 2.0), and thereafter, 300 cc of aqueous ammonia solution was placed, followed by stirring for 5 minutes (pH 7.4) was performed 3 times.
  • An aqueous slurry solution of the obtained aluminum hydroxide was filtered to recover a cake, subjecting the cake to a washing operation in which the cake was re-dispersed in 7 L of pure water, followed by filtering again was performed twice, obtaining a washed gel.
  • the washed cake was air dried to adjust the moisture, and then was formed into a rod-like shape having a diameter of 1.6 mm with an extruder.
  • the resultant was dried (120° C., 3 hours), crushed to about 1 cm in length, calcined in a muffle furnace (500° C., 3 hours), thereby yielding an alumina carrier D containing sulfur. At this time, the sulfur content remaining in the carrier D was about 0.5%.
  • the alumina carrier D thus obtained had a BET surface area of 300 m 2 /g, a pore volume of 0.46 cm 3 /g, and an average pore size of 5.6 nm, which were determined by a mercury porosimetry, and had a sharp pore distribution in which the pore sizes of almost all of the pores were concentrated near the average pore size.
  • the volume occupied by pores having a diameter of 4 to 6 nm was 80% or more of the total pore volume.
  • the pore distribution of the carrier D is shown in FIG. 6.
  • the alumina carrier D thus prepared was impregnated with an aqueous chloroplatinic acid solution whose pH was adjusted to 2.0 so that the platinum-loaded amount after calcination was 0.6% by weight. Thereafter, moisture was removed with an evaporator, and the resultant was dried (at 120° C. for 3 hours) and calcined (at 400° C. for 3 hours). Then, the resultant was placed in a flow-type hydrogen-reducing apparatus, and hydrogen reduction was carried out at 450° C. for 15 hours in a hydrogen stream, thereby yielding a 0.6 wt % platinum-loaded alumina catalyst No. 4.
  • both the sulfur elements and the platinum elements are substantially uniformly dispersed throughout the carrier also in a catalyst prepared using an alumina carrier in which sulfur is incorporated by synthesizing the carrier using sulfate for an alumina source, and removing excessive sulfate groups by washing in the preparation process of the alumina carrier and that the distribution pattern of the platinum elements are substantially in agreement with the distribution pattern of the sulfur elements.
  • Supports A containing no sulfur were impregnated with an aqueous ammonium sulfate solution with a concentration of 0.38 mol/L so that the sulfur content after calcination of the resultants were 0.1% by weight, 0.5% by weight, or 1.2% by weight, respectively, and then, each solvent was removed with an evaporator.
  • the resultants were dried (120° C., 3 hours), and calcined (500° C., 3 hours), thereby yielding an alumina carrier E (0.1% by weight), an alumina carrier F (0.5% by weight), and an alumina carrier G (1.2% by weight) each containing sulfur.
  • Each of the alumina carriers E and F thus prepared was impregnated with an aqueous chloroplatinic acid solution whose pH was adjusted to 2.0 so that the platinum loading amount after calcination was 0.6% by weight. Thereafter, moisture was removed with an evaporator, and the resultants were dried (at 120° C. for 3 hours) and calcined (at 400° C. for 3 hours). Then, the resultants were placed in a flow-type hydrogen-reducing apparatus, and hydrogen reduction was carried out at 450° C. for 15 hours in a hydrogen stream, thereby yielding a 0.6 wt % platinum-loaded alumina catalysts No. 5, No. 6, and No. 7. With respect to the obtained catalysts No. 5, No. 6, and No.
  • the dispersion ratio of platinum of each of the catalysts No. 1 to No. 7 prepared in Comparative Example and Examples 1 to 3 above was measured by a CO pulse adsorption method.
  • the CO pulse adsorption method will be described below.
  • the CO is adsorbed on the surface of loaded metal and the amount of eluted CO is small in the early stage of the injection.
  • the CO is adsorbed on almost the entire surface of the loaded metal, and almost all of the injected CO is eluted in a steady state.
  • the amount of eluted CO at the time of the first adsorption is subtracted from the amount of eluted CO in the steady state, and the sum of the differences is defined as the CO adsorption amount.
  • the CO pulse adsorption method refers to a method for calculating a metal surface area, dispersion ratio, and particle diameter from the adsorption amount and the loaded metal content. The calculation method is specifically described below.
  • the adsorption gas amount V per g of catalyst at 0° C. was calculated from the CO gas amount Vt in which a sample amount of catalyst W(g) was adsorbed at a measurement temperature according to the following equation (1).
  • V (Vt/W) ⁇ 273/(273+t) ⁇ (ml/g ⁇ cat) (1)
  • K V/(22.4 ⁇ 10 ⁇ 3 ⁇ 10 6 ) (mol/g ⁇ cat) (3)
  • the dispersion ratio B (proportion of effective surface metal in the loaded metal) is calculated according to the following equation (4).
  • B (K/R) ⁇ 100(%) (4)
  • the lattice constant of the loaded metal catalyst is defined as a (( ))
  • a carrier A containing no sulfur and a carrier D containing sulfur were impregnated with an aqueous ammonium rhodium hexachloride solution for 50 hours, and then the solvents were removed with an evaporator.
  • the resultants were dried (at 120° C. for 3 hours), thereby and calcined (at 400° C. for 3 hours), thereby yielding a 0.6 wt % rhodium-loaded alumina catalysts.
  • the concentrations of sulfur element and platinum element on each of the catalyst cross sections were quantified by surface analysis and line analysis using EPMA. The results are shown in FIG. 11 .
  • 10 cc of each catalyst above was placed in a stainless steel reaction tube whose inside diameter is 12.6 mm ⁇ 300 mm and which is equipped with a protective tube for a thermocouple whose outer dimension was 1 ⁇ 8 inch in the center of the cross section of the reaction tube in such a manner that the center of a catalyst bed was positioned in the longitudinal center of the reaction tube, and 10 cc of ⁇ -alumina beads with a diameter of 1 mm ⁇ was placed on the upper side of the catalyst as a preheating layer.
  • HPLC high speed liquid chromatography
  • a hydrogen flow rate was adjusted so that the hydrogen gas amount was adjusted to 5 mol % with respect to the total amount of MCH and hydrogen gas.
  • the reaction test was performed while adjusting the output of an electric furnace so that the central temperature of a catalyst bed was 320° C. during the reaction.
  • a vapor-liquid separator was placed at the outlet of the reaction tube, and the resultant was separated into a liquid reaction product such as toluene and gas such as hydrogen gas, which were generated by the dehydrogenation reaction.
  • the collected liquid product and gas were separately analyzed by gas chromatography.
  • the dehydrogenated catalyst of the present invention shows notably high selectivity and markedly low concentration of methane, which is generated by a side reaction, compared with a catalyst prepared from an alumina carrier containing no-sulfur, even if the acid site is not masked using alkali metal such as potassium. Moreover, considering that stable performances are maintained over 300 hours and deactivation in catalyst performances is not observed, hydrogen can be stably generated with favorable selectivity over a long period of time.
  • the uniformly, highly dispersed metal catalyst of the present invention catalyst metal is loaded on a catalyst carrier in a state where the catalyst metal is uniformly dispersed throughout the catalyst carrier. Therefore, the loading amount of the catalyst metal increases and excellent performances are exhibited in terms of catalytic activity, selectivity, life, etc.
  • the uniformly, highly dispersed metal catalyst of the present invention is suitably used as a dehydrogenation catalyst for a hydrogen storage for use in a chemical hydride hydrogen supply system and the like, and suitably used for manufacturing chemical products, producing hydrogen, cleaning the environment, such as cleaning of exhaust gas.
  • such a uniformly, highly dispersed metal catalyst can be readily manufactured industrially.

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